One problem related to door hinge has been reported for the 2001 Ford Explorer Sport. The most recently reported issues are listed below.
Regarding "side-steps" or "rails" that begin to rust at joints and flat surface area within as little as two years of new vehicle delivery. Witnessed variety of various Ford vehicles that were late model year of '02 & earlier that have this problem. Appears to be a systemic nationwide problem particularly in areas with winter months. Contacted dealer and asked if they would cover this issues under 5year Ford corrosion coverage, but they refused to, stetting this does not constitute "perforation" of vehicle body. First concern, is rust forming and weakening the structure which may give way under pressure. Since there are others who are experiencing the same problem, Ford should replace or repair these "side-steps" at no charge to the owners' and correct the root cause of this problem by properly manufacturing and producing this accessory item.